Glass manufacturing apparatus and method

ABSTRACT

An apparatus and method for manufacturing glass containers handles the containers individually after a hot forming process and annealing to prevent glass-to-glass contact. By handling the containers individually and preventing glass-to-glass contact damage to the containers in the form of checks and scratches is avoided. To prevent contact of the containers and damage arising from the contact, the equipment including conveyors, pushers, starwheels, shuttles, and transfer heads that move the glass containers through the apparatus maintains the glass containers in uniform spaced relationship at each stage of container processing until the containers are packaged.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.62/702,032, filed Jul. 23, 2018, the entirety of which is incorporatedherein by reference.

TECHNICAL FIELD

The present invention relates to the field of glass manufacturing andparticularly to the apparatus and method for handling glass containersfollowing molten formation and discharge from a lehr where thecontainers are cooled and annealed. The apparatus is specially designedto ensure that the containers are handled individually to avoidglass-to-glass contact during inspection and packaging.

BACKGROUND

In the course of manufacturing glass containers in a hot forming processthat either starts with a molten glob of glass material which is moldedto shape or starts with a tubular glass body that is heated to a moltenstate and then formed into a container shape, the hot glass generallypasses through an annealing oven or lehr to remove stresses from themolding or molding process.

In the past the manufacture of glass containers in high volume using theprocess described above the containers were handled in mass, that is,the containers while still warm were handled as a group gatheredtogether in contacting relationship with one another at various stagesof processing after annealing. The pushing and bumping of the glasscontainers against one another while still warm caused checks andscratches in the glass container. Such checks and cracks are flaws inwhat is supposed to be a flawless container, and can interfere withsubsequent processing of the containers in filling lines, and therebyrender the container useless.

For example, it is customary in filling glass vials with pharmaceuticalproducts to inspect each vial for proper filling by projecting a beam oflight against one side of the container and detecting the projected beamemerging for the opposite side for consistency with the pharmaceuticalfilling inside. If the container itself has a check or crack, theemerging beam of light could be affected and falsely indicate adefective filling. Accordingly, glass containers being fed to a fillingline should be flawless to begin with. This requirement in turn makesdemands on the processing of the glass containers at the manufacturinglevel.

Accordingly, it is an object of the present invention to produce glasscontainers without flaws through improvements in the handling of thecontainers at the manufacturing level.

SUMMARY

In accordance with the object, the improvement in the handling of theglass containers begins with the transfer of the containers from theconveyor advancing the containers through the annealing oven or lehr.Generally, the containers are positioned on the lehr conveyor in spacedbut not necessarily in uniform spaced relationship.

To this end, one aspect of the invention comprises an apparatus formanufacturing glass containers having a transfer head that carries glasscontainers from the cold end of a lehr conveyor where the rows of glasscontainers are not in uniform spaced relationship, to a second conveyorthat carries a sequence of the glass containers in uniform spacedrelationship for subsequent processing. A deadplate is interposedbetween the first conveyor and the second conveyor. The transfer head ismounted above the dead plate and the first conveyor is movable betweenthe deadplate and the first conveyor for transferring glass containersfrom the first conveyor where the glass containers are not in uniformspaced relationship to the deadplate and depositing the containers onthe deadplate in uniform spaced relationship. To bring about order tothe positioning of the containers relative to one another, the transferhead has uniformly spaced pockets for receiving glass containers in arow on the first conveyor and positioning the containers of the row onthe deadplate in uniform spaced relationship.

A pusher bar is movably mounted over the deadplate for pushing the glasscontainers deposited on the deadplate by the transfer head onto thesecond conveyor while maintaining the uniform spaced relationship. Thepusher bar has pockets that are uniformly spaced to correspond to theuniformly spaced pockets on the transfer head.

In another aspect of the invention, the glass manufacturing apparatusand method produces the glass containers in a continuous process betweena lehr for annealing the glass containers after hot glass formation, aninspection station for examining the annealed containers for defects,and a packaging station where a plurality of the glass containers areplaced in packages. A series of conveying mechanisms are configured tomove the glass containers from the lehr through the inspection andpackaging stations while maintaining the containers in spaced,non-contacting relationship with each other. A programmable logiccontroller is connected with the inspection station, the packagingstation, and the series of conveying mechanisms to advance the glasscontainers between the stations and within the stations in timedrelationship and to maintain a spaced relationship between thecontainers.

In still a further aspect of the invention, an apparatus for producingglass containers has an inspection station receiving, inspecting, anddischarging glass containers in sequence. The inspection station has arejection mechanism for ejecting from the sequence any container thatdoes not pass inspection. At the output of the inspection station, adischarge conveyor is connected with the inspection station forreceiving the glass containers discharged after passing inspection. Thedischarging conveyor conveys the glass containers away from theinspection station in a consecutive sequence of containers inpredetermined spatial relationship with one another.

For this purpose, a controller is connected in controlling relationshipwith the inspection station and the conveyor and interrupts theoperation of the discharge conveyor whenever a container is ejected fromthe sequence by the rejection mechanism. In this manner, a consecutivesequence of containers in predetermined spatial relationship ismaintained on the conveyor.

In still a further aspect of the invention, apparatus is provided forplacing individual articles, such as the glass containers, in a packagesuch as a cell pack. The apparatus has a conveyor for conveying a seriesof articles to a packaging station. First and second shuttles aredisposed adjacent the conveyor at the packaging station, and eachshuttle is movable back and forth between a loading position and anunloading position. A controlled drive mechanism is connected with thefirst and second shuttles to move the shuttles between the loading andunloading positions in alternating fashion, whereby one shuttle can beloaded with articles at the loading position while the other shuttle isunloaded at the unloading position. A package table is placed at theunloading position of the shuttles and supports the cell pack havingindividual cells for receiving individual articles.

Each shuttle has a number of pockets for receiving a correspondingnumber of articles from the conveyor at the loading position andtransferring the articles to the unloading position. A shuttle loader atthe loading position is configured to transfer the articles from theseries on the conveyor to the pockets of the first and second shuttles.

A shuttle unloader at the unloading position of the shuttles isconfigured to transfer the articles from the pockets of the shuttles tothe cells of the cell pack on the packaging table. The shuttle unloaderhas a transfer head configured to engage each individual article in apocket of the first or second shuttle at the top of the article forlifting, transferring, and lowering of each individual article into anindividual cell of a cell pack on the packaging table.

By handling the glass containers individually between annealing in thelehr and the packaging at the packaging station, checks and scratches inthe containers are minimized or eliminated entirely.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing the output portion of an apparatusfor manufacturing glass containers from the front.

FIG. 2 is a perspective view of the apparatus in FIG. 1 from the rear.

FIG. 3 is a top plan view showing the arrangement of the variousprocessing stations for the glass containers in the apparatus of FIG. 1.

FIG. 4 is a block diagram illustrating the controls for synchronizingthe various operations of the glass manufacturing apparatus in FIG. 1.

FIG. 5 is a schematic perspective view of the portion of apparatus fortransferring glass containers from a lehr conveyor to an inputdeadplate.

FIG. 6 is a detailed view of a transfer head used in FIG. 5.

FIG. 7 is a perspective view of the input deadplate and pusher bar formoving the glass containers onto an input conveyor for furtherprocessing of the glass containers.

FIG. 8 is a perspective view of the input conveyor feeding glasscontainers into the starwheel at an inspection station in the glassmanufacturing apparatus.

FIG. 9 is perspective view of a shuttle system at the packaging stationof the glass manufacturing apparatus for loading glass containers into acell pack.

FIG. 10 is a perspective view of a shuttle loader at the loadingposition of the packaging station for loading glass containers intoshuttles.

FIG. 11 is a perspective view of the shuttle unloading position of thepackaging station where glass containers are transferred from theshuttles to a cell pack.

FIG. 12 is a perspective view of a transfer head for transferring glasscontainers from the shuttles to a cell pack.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1, 2, and 3 show a general arrangement of a glass manufacturingapparatus 10 between a curing oven or lehr (not illustrated) forannealing glass containers C after formation and a packaging station forthe glass containers. The glass containers C may initially have beenformed from glass tubes or molten glass gobs in a blow molding process,and are composed of a silicate material, typically a borosilicate. Thenewly formed containers are generally hot and require heat treatment orannealing in a lehr to eliminate internal stresses and improve fractureresistance.

A lehr unloading section 12 is located generally in the middle of theglass manufacturing apparatus 10 and receives the glass containers Cfrom the lehr. The containers are then fed into an inspection station 14where the containers are inspected for cosmetic defects. From theinspection station 14 the glass containers are moved to a packagingstation 16 where the containers are loaded into cell packs. Although theillustrated apparatus 10 places the lehr unloading section 12 in themiddle of the apparatus, other arrangements are also possible. Forexample the lehr unloading section 12, the inspection station 14, andthe packaging station 16 could be laid out in a linear array in thatorder if space is available.

The movement of the glass containers C between the various stations andthe operations at each station are coordinated and controlled by acentral programmable logic controller (PLC) 20 shown in FIG. 4. Themovement of the glass containers is accomplished by various conveyingmechanisms described below. The operations of the conveying mechanismsare timed to move the containers appropriately for the operations to beperformed at each station, and to maintain the containers in uniformspaced relationship with one another throughout the movements. Bycontrast, in prior art systems the glass containers were pushed togetherat various stations and then handled separately when the stations wereready to perform the intended functions. It has been determined that theglass-to-glass contact of the containers when handled in groups cancause checking or scratching which interferes with later inspectionprocesses and lowers the fracture strength of the glass containers, thatis, the resistance of the glass containers to fracture. By controllingthe various operations of the apparatus 10 and movement of the glasscontainers through the apparatus in timed relationship with one anotherthrough the PLC 20, maintaining the glass containers in spacedrelationship through the various manufacturing operations is possible,and defects in the glass containers are substantially reduced oreliminated entirely.

FIG. 5 illustrates the mechanisms for unloading the glass containers Cfrom the discharge end of a lehr conveyor 22 and transferring thecontainers to an input conveyor 24 which feeds the containers one-by-onetoward subsequent operations of the apparatus. The glass containers C atthe discharge end of the lehr conveyor 22 are illustrated in rows, butin practice the containers are generally not uniformly spaced from oneanother. Additionally the containers move on the lehr conveyor at asteady speed during annealing of the glass. Consequently, in order tobring about an orderly arrangement of the containers for subsequentoperations, a transfer head 26 is suspended from a moveable gantry 28above the discharge end of the conveyor and a deadplate 30 where thecontainers are deposited by the head with a uniform spacing. Thesequence of movements of the transfer head 26 by the gantry 28 along apath 25 between the lehr conveyor 22 and the deadplate 30 is illustratedby the letter sequence a, b, c, d, e, f, g, h, i, j, and k at variouspositions on the path and is controlled by the PLC 20 of FIG. 4.

To bring about a uniform arrangement of the containers on the deadplate30 from the non-uniform arrangement on the lehr conveyor 22, thetransfer head 26 is designed with V-shaped pockets 32 as shown in FIG.6. Each of the pockets is sized to receive one glass container C as thecontainers on the lehr conveyor and the head move toward one another.The V-shaped pockets 32 are uniformly spaced along the head 26 so thatany non-uniform spacing of the containers in a row on the lehr conveyoris rectified by the time the containers C are captured in the pockets.The pockets 32 may be formed in a firm resilient material 27, such asthe thermoplastic Delrin, or a plastic foam material mounted on abacking plate 29 to protect the containers from being scratched whencaptured in the pocket and during transfer to the deadplate 30.

In addition, each of the pockets 32 of the transfer head 26 has a vacuumport 34 which is activated by the PLC 20 to draw a container into thepocket and firmly hold the container in the head as the head removes thecontainer from the lehr conveyor 22 onto the deadplate 30. As analternative to the vacuum port, each pocket could be provided with amechanical capturing arrangement, but the “soft” engagement by aresilient pocket material and vacuum is preferred. The vacuum port mayalso be distributed around the container C if the pocket is constructedby an open-cell foam material.

After the glass containers C are deposited on the deadplate 30 by thetransfer head 26, the vacuum holding the containers is released, and thetransfer head is moved from position h to i shown in FIG. 5. Thecontainers are then positioned by the transfer head on the deadplate 30in a starting position in front of a pusher bar 36 which is driven by aservomotor 38 as shown in FIG. 7. The pusher bar 36 is constructed in amanner similar to the transfer head 26 although the bar faces toward theinput conveyor 24 rather than the lehr conveyor 22. The pusher bar maybe provided with pockets corresponding to the pockets 32 on the transferhead, although the pockets on the pusher bar need not be as deep becausethe containers C are positioned by the transfer head on the deadplate ina row with uniform spacing at the starting position in front of thepusher bar. Additionally, the pusher bar does not require vacuum portsin the pockets for holding the containers.

With the containers C positioned on the deadplate at the startingposition as shown in FIGS. 5 and 7, and the transfer head moved out ofthe way to position j by the PLC 20 of FIG. 4, the pusher bar 36 isactivated by the PLC and pushes a row of containers C from the startingposition at one end of the deadplate to the other end and onto the inputconveyor 24 against a stop 40. The stop 40 may be a relatively hard stopto position the containers accurately in spaced relationship on theconveyor. The stop can be made with a firm material, such Delrinthermoplastic, to protect the containers from scratching or checking.

The operations of the input conveyor 24 and the pusher bar 36 are alsocoordinated by the PLC 20 as shown in FIG. 4 so that the conveyormovement is halted while the pusher bar pushes a row of containers Conto the conveyor. The pusher bar then returns to the starting position,and the conveyor moves the glass containers toward further operationswith the containers positioned in uniformly spaced relationship on theconveyor in a sequence established by the transfer head 26.

In one form, the input conveyor 24 is a vacuum belt conveyor shown insection in FIG. 8. The conveyor comprises an air permeable belt 44 thatis driven over a vacuum manifold 46 with guide pulleys 48 by aservomotor 50. The vacuum drawn through the air permeable belt creates avacuum force that holds the glass containers C on the belt in fixedpositions and non-contacting relationship that is established when thecontainers are loaded onto the conveyor by the pusher bar 36.

Alternatively, the input conveyor belt could have a series ofcompartments to hold individual containers in spaced relationship.Loading of the containers into the compartments would require precisepositioning of the belt to match the positions of the containers.However, precise positioning is also required with vacuum belts if theseries of containers on the conveyor is to retain the uniform spacingthroughout the length of the series.

As shown in FIGS. 3 and 8 the input conveyor 24 delivers the glasscontainers C to the inspection station 14 where a number inspectionsteps are performed on the containers. For this purpose, the inspectionstation has a starwheel 60 with pockets 62 at the periphery of the wheelfor engaging the containers at a pickup point at the end of the inputconveyor 24. The starwheel is driven by a servomotor 64 under thecontrol of the PLC 20 of FIG. 4. Each pocket has a vacuum port 66 tocapture a container C from the conveyor, and hold the container in anexposed relationship with a number of inspection devices (not shown) ofknown types distributed around the periphery of the wheel. Theinspections are performed to detect gauging and cosmetic defects in thecontainers, and if a defect is found such that the container does notpass inspection, the container is ejected through a rejection chute 68shown in FIG. 3. The release of a defective container from the pocket ofthe starwheel is coordinated between the inspection device and thevacuum port holding the defective container by the PLC 20 of FIG. 4.

To facilitate the transfer of the glass containers C from the inputconveyor 24 to the starwheel 60 at the pickup point, the vacuum manifold46 has a variable cross sectional area and the area is reduced at thepickup point at the end of the conveyor 24 as shown in FIG. 8. With thereduced cross sectional area the vacuum force holding a container C onthe air permeable belt 44 is reduced, and the vacuum force generated inthe pocket 62 of the starwheel overcomes the force through the belt.Thus, a container C is transferred from the input conveyor 24 to thestarwheel 60.

Additionally, the movement of the input conveyor 24 and the rotation ofthe starwheel 60 are coordinated and synchronized by the PLC 20 of FIG.4 so that a pocket 62 of the starwheel is present at the pickup point atthe end of the conveyor at the same time as the glass container C on theconveyor. The movement and rotation may be continuous or incremental. Toaid in the synchronization, a container sensor 70 is positioned alongthe input conveyor, and is connected with the PLC to detect and signalthe presence of a glass container in the sequence of containers on theconveyor. If a glass container is detected by the container sensor 70the sensor sends a signal to the PLC. The PLC is programmed to cause thestarwheel to rotate a pocket 62 into the pickup point and pickup thecontainer. In the event that the presence of a glass container is notdetected in the sequence by the container sensor, the PLC is programmedto interrupt the starwheel rotation until a container is eventuallyspotted.

It should be noted that the interruption of the starwheel rotation bythe PLC 20 when the presence of a glass container in the sequence is notdetected ensures that each pocket 62 of the starwheel 60 is loaded witha container. Hence, a continuous sequence of glass containers C isloaded onto the starwheel in the inspection station 14 from the inputconveyor 24 even if a container is missing from the sequence on theconveyor.

FIG. 3 shows a discharge conveyor 80 leading from the starwheel 60 inthe inspection station 14 to the packaging station 16. Movement of thedischarge conveyor like the input conveyor 24 and the starwheel 60 iscontrolled by the PLC as indicated in FIG. 4. The discharge conveyor 80is preferably a vacuum belt conveyor constructed like the input conveyor24 with an air permeable belt overlying a vacuum manifold. Air drawnthrough the air permeable belt creates a vacuum force that holds theglass containers C in place on the conveyor. However, the dischargeconveyor can take other forms such as mechanical pockets which hold thecontainers in uniformly spaced relationship.

The discharge conveyor 80 has a pickup point at the periphery of thestarwheel at which the glass containers are transferred from thestarwheel to the discharge conveyor by release of the vacuum in thepocket preferably supplemented by a jet of pressurized air to release acontainer from the starwheel and capture the container by way of vacuumforce drawn through the air permeable conveyor belt. The vacuum releaseand movement of the belt on the discharge conveyor are also controlledby the PLC 20.

Also shown in FIG. 3 is the rejection chute 68 through which defectiveglass containers are ejected for failing inspection at some point in theinspection station 14. It will be understood that the ejection of aglass container from a pocket 62 of the starwheel 60 leaves an emptypocket and no container to be transferred to the discharge conveyor 80when the empty pocket reaches the pickup point. The PLC receives signalsof the ejections of containers, tracks movements of the empty pockets onthe starwheel in a two-way communication link between the inspectionstation 14 and the PLC. Hence, the PLC is aware of empty pocketsreaching the pickup point with the discharge conveyor 80. Alternatively,or additionally, a container sensor like the container sensor 70 can bepositioned at the pickup point for the discharge conveyor to signal theabsence of a container in the pocket 62 of the starwheel. Accordingly,the PLC interrupts the movement of the discharge conveyor when an emptypocket of the starwheel reaches the pickup point and does not resumemovement until a pocket occupied by a glass container arrives at thepickup point and the glass container is transferred to the dischargeconveyor. Hence, the synchronization of the starwheel rotation and thedischarge conveyor movement by the PLC produces a continuous sequence ofuniformly spaced glass containers C on the discharge conveyor 80 inspite of the rejection of a glass container in the inspection station14.

It should also be noted as described above that the rotation of thestarwheel 60 is interrupted by the PLC in the event that a container Cis not detected by the container sensor 70 located along the inputconveyor 24. Thus the absence of a container in the sequence ofcontainers approaching the starwheel 60 and the rejection of a containerin the inspection station 14 are noted and compensated for by the PLC byinterrupting rotation of the starwheel 60 or movement of the dischargeconveyor 80 to ensure that a continuous sequence of uniformly spacedcontainers C in non-contacting relationship is formed on the dischargeconveyor.

FIG. 3 shows that the discharge conveyor 80 carries the continuoussequence of glass containers C in uniformly spaced, non-contactingrelationship from the inspection station 14 to the packaging station 16.

FIG. 9 illustrates the details and handling of the glass containers C atthe packaging station 16. The packaging station has a first shuttle 84and a second shuttle 86 that are positioned at opposite sides of thedischarge conveyor 80 delivering the glass containers from theinspection station 14. The first shuttle 84 is driven back and forth bya servomotor 88 between a shuttle loader 90 at a shuttle loadingposition 92, where the shuttle 84 is shown in FIG. 9, and a shuttleunloading position 94. The second shuttle 86 is driven back and forth bymeans of a servomotor 98 between the shuttle loader 90 at the shuttleloading position 92 and the shuttle unloading position 94, where theshuttle 86 is shown in FIG. 9. Both servomotors 88, 98 are controlled bythe PLC to move the shuttles 84, 86 between the shuttle loading position92 and the shuttle unloading position 94 in alternating fashion.Specifically, the first shuttle 84 is moved to the loading position 92to receive glass containers C from the discharge conveyor 80, while thesecond shuttle 86 is moved to the shuttle unloading position 94 forunloading the containers from the shuttle 86. Then the shuttle positionsare reversed so that the second shuttle 86 is moved to the shuttleloading position 92 to receive glass containers C from the dischargeconveyor 80 while the first shuttle 84 is moved to the shuttle unloadingposition for unloading the containers from the shuttle 84. The loadingof one shuttle while the other shuttle is unloaded reduces the packagingprocess time.

FIG. 10 shows the shuttle loader 90 and the shuttles 84, 86 on oppositesides of the discharge conveyor 80 at the shuttle loading position 92for purposes of illustration. It should be understood, however, that theshuttles are loaded alternately as described above, and accordingly bothshuttles are not normally positioned at the loading position 92 at thesame time.

The first shuttle 84 has a number of pockets 84 a with openings facingthe discharge conveyor 80 in order to receive a corresponding number ofglass containers C from the conveyor. For this purpose, the shuttleloader 90 is comprised of a pusher bar 100 suspended immediately abovethe conveyor 80 at the loading position 92 by a beam 102 that ismoveable back and forth in a direction transverse to the conveyor by aservomotor 104 controlled by the PLC 20 as shown in FIG. 4. The pusherbar 100 preferably pushes the glass containers C in the series on theconveyor 80 one at a time between fence blocks 106 into a pocket 84 a ofthe first shuttle 84 starting at one end of the shuttle. Since theloader is fixed at the loading position, after each container C isloaded into a pocket 84 a, the conveyor 80 is indexed by one incrementequal to the spacing of the containers on the conveyor by the PLC 20. Atthe same time the shuttle is indexed by the PLC by an amount equal tothe spacing of the pockets so that an empty pocket is positionedadjacent the pusher bar to receive the next container in the series. Byincrementing the conveyor and the shuttle separately, the spacing of theglass containers on the conveyor need not match the spacing of thepockets on the shuttle. Alternatively, if the spacing of the containersand the pockets match, the pusher bar could be longer and push multiplecontainers as a group into the correspondingly spaced pockets of theshuttle.

After each of the pockets 84 a is loaded with a glass container, thefirst shuttle 84 is moved to the shuttle unloading position 94 in FIG.9.

The second shuttle 86 has a construction similar to the construction ofthe first shuttle 84 except that the openings of the pockets 86 a facethe conveyor 80 from the opposite side of the conveyor. Glass containersC are also loaded into the pockets 86 a of the second shuttle 86 insubstantially the same manner as the first shuttle 84 by pushingmovements of the pusher bar 100 and indexing movements of the conveyor80 and shuttle 86. The pusher bar however pushes the containers from theopposite side of the containers into the pockets 86 a. After the secondshuttle 86 is loaded, the second shuttle is moved to the unloadingposition 94, and the first shuttle 84 is moved to the loading positionas shown in FIG. 9. All the operations of the shuttles 84, 86, theconveyor 80, and the pusher bar 100 are synchronized by the PLC 20 inFIG. 4.

FIG. 11 illustrates the shuttle unloader 120 that unloads both the firstand second shuttles 84, 86 at the shuttle unloading position 94 alsoshown in FIG. 9. The shuttle unloader is comprised of a transfer head122 suspended from a moveable gantry 124 above the shuttle unloadingposition 94 and the packaging station 16. The shuttle unloader 120 isconnected in controlling relationship with the PLC 20 as indicated inFIG. 4, and as a consequence the PLC controls the timing and operationsof the transfer head 122 and the moveable gantry 124.

As shown in FIG. 11 both shuttles 84 and 86 loaded with glass containersC are shown at the unloading position for purposes of illustration.However, as explained above, the shuttles are operated in an alternatingfashion between the loading position 92 (FIG. 9) and the unloadingposition 94. As a consequence, only one shuttle loaded with glasscontainers will appear at the unloading position 94 at one time, and theother shuttle will appear at another time. Nonetheless the illustrationof FIG. 11 will suffice to explain the unloading of either shuttle.

In unloading the glass containers C from the shuttle 84, the gantry 124initially moves the transfer head 122 along the trajectory path 126 inFIG. 11 to a pickup position overlying the shuttle 84 and the containersin the shuttle. The transfer head 122 shown in one embodiment in FIG. 12is a vacuum head having a plurality of vacuum cups 130 arranged linearlyalong the bottom edge of the head. The spacing of the cups matches thespacing of the pockets 84 a in the shuttle and correspondingly theuniform spacing of the containers C in the pockets. Accordingly, whenthe vacuum cups are positioned over the glass containers and activated,the tops of the glass containers are engaged and captured in the cupsand the containers are then lifted from the pockets when the transferhead rises as shown in FIG. 12. Of course other forms of heads thatcapture the glass containers mechanically, preferably at the tops, canbe employed.

As shown in FIG. 11 the captured containers are moved by the transferhead 122 along the trajectory 126 to a placement position over thepackage 134, which is illustrated as a cell pack. The cell pack is apackage with individual cells having the same spacing as the glasscontainers C in the transfer head. A cell pack ensures that theindividual glass containers do not come into contact with one anotherand avoids scratches or checks during shipping and handling.

The transfer head 122 in FIG. 12 is a head with a tilting feature. Thevacuum cups are pivotally mounted to the head about an axis 136 and aretilted collectively by an actuator 138 about the axis to bring the glasscontainers into alignment with the axes of the cells in the cell packfor ease of inserting the containers into the pack. With the glasscontainers safely inserted into the cells, the vacuum cups 130 aredeactivated to release the containers, and the transfer head is drawnaway from the package 134.

With a first group of glass containers C unloaded from the shuttle 84and stowed for example in the bottom row of cells in the package 134,the transfer head 122 is moved by the gantry 124 along the trajectory128 to a position overlying the shuttle 86 at the unloading position 94in preparation to unload a second group of glass containers from theshuttle. The second group of containers are stowed in the second row ofcells in the package 134 in the same manner as the first group in thefirst row. However, if the number of cells in the cell pack canaccommodate more glass containers than are held in the transfer head122, the gantry 124 can move the transfer head laterally to fill theadditional cells in the same row. The unloading of glass containers Cfrom the shuttles 84, 86 continues under the control of the PLC untilall the rows of the cell pack are filled.

FIGS. 1-3 illustrate multiple cell packages 134 mounted on a rotatableturret 140. Consequently, when one package is fully loaded with glasscontainers, the turret is rotated under the control of the PLC andadditional packages can be loaded with glass containers from the glassmanufacturing apparatus. With the described apparatus a high volume ofglass containers can be produced without glass-to-glass contact that cancause defects in the glass.

While in the present application preferred embodiments of the inventionare described, it is to be clearly pointed out that the invention is notlimited thereto and that the invention can also be carried out in otherways within the scope of the following patent claims.

What is claimed is:
 1. An apparatus for manufacturing glass containerscomprising: a first conveyor that carries multiple rows of glasscontainers that are not in uniform spaced relationship, a secondconveyor that carries a sequence of the glass containers in uniformspaced relationship for subsequent processing; a deadplate interposedbetween the first conveyor and the second conveyor; a transfer headmounted above the dead plate and the first conveyor and movable betweenthe dead plate and the first conveyor for transferring glass containersfrom the first conveyor where the glass containers are not in uniformspaced relationship to the deadplate and depositing the containers onthe deadplate, the transfer head having uniformly spaced pockets forreceiving glass containers in a row on the first conveyor andpositioning the containers of the row on the deadplate in uniform spacedrelationship, the uniformly spaced pockets of the transfer head beinggenerally V-shaped pockets; and a pusher bar movably mounted over thedeadplate for pushing the glass containers deposited on the deadplate bythe transfer head onto the second conveyor in uniform spacedrelationship, the pusher bar having generally V-shaped pockets that areuniformly spaced to correspond to the pockets of the transfer head forreceiving the glass containers and maintaining the uniform spacedrelationship of the glass containers when the containers are pushed ontothe second conveyor.
 2. An apparatus for manufacturing glass containersas defined in claim 1 wherein: each of the uniformly spaced pockets ofthe transfer head has a vacuum port for drawing a glass container on thefirst conveyor into the pocket whereby the glass containers are held bythe transfer head in uniform spaced relationship.
 3. An apparatus formanufacturing glass containers as defined in claim 1 wherein theuniformly spaced pockets of the transfer head are generally V-shapedpockets.
 4. An apparatus for manufacturing glass containers as definedin claim 1 wherein the pusher bar has pockets uniformly spaced tocorrespond to the pockets of the transfer head for maintaining theuniform spaced relationship of the glass containers when the containersare pushed onto the second conveyor.
 5. An apparatus for manufacturingglass containers as defined in claim 4 wherein the pockets of the pusherbar are V-shaped pockets.
 6. An apparatus for manufacturing glasscontainers as defined in claim 1 wherein the second conveyor is a vacuumbelt conveyor configured to hold the containers on the second conveyorin the uniform spaced relationship when the glass containers are pushedonto the second conveyor by the pusher.
 7. An apparatus formanufacturing glass containers as defined in claim 6 further including aprogrammable logic controller connected with the pusher and the secondconveyor to coordinate the pushing of the containers onto the secondconveyor and the movement of the second conveyor to maintain the uniformspacing in the sequence of glass containers on the second conveyor. 8.An apparatus for manufacturing glass containers as defined in claim 7wherein the pusher and deadplate are located at one side of the secondconveyor to cause the glass containers to be pushed from the deadplateinto the sequence of containers on the second conveyor from the oneside.
 9. An apparatus for manufacturing glass containers as defined inclaim 7 wherein the programmable logic controller halts the movement ofthe second conveyor during the pushing of the glass containers onto thesecond conveyor.